Time fault circuit interrupter

ABSTRACT

An exemplary time fault circuit interrupter for interrupting a power supply to an equipment unit upon the occurrence of a trip condition may include a sensor configured to monitor a current flow to the equipment unit. The circuit interrupter may also include a trip mechanism configured to interrupt the current flow. The circuit interrupter may further include a processor in communication with the sensor and the trip mechanism, and the processor may be configured to cause the trip mechanism to interrupt the current flow when a current flow time has reached a predetermined time limit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.15/715,691 filed Sep. 26, 2017 and is hereby incorporated by referencein its entirety.

FIELD OF TECHNOLOGY

The present disclosure pertains to a time fault circuit interrupter forinterrupting a power supply to an equipment unit, including, but notlimited to, a pump, based on a current flow time.

BACKGROUND

Water damage is a problem encountered by homes every year and can rangefrom insignificant to quite severe. Thus, the costs for homeownersand/or insurance companies to repair such damage can be extremely high.Water damage can be caused by many different factors. One such factorcould be the operation of a piece of equipment, such as a pump, forlonger than is needed. For example, a well pump that is left operatingcan ultimately flood a home. In addition, other types of equipment,including, but not limited to, pumps, air compressors, and the like,that are left operating can potentially cause other kinds of damageand/or have their motors or other components fail due tolonger-than-necessary operation.

Accordingly, there exists a need for a device, system, and/or method tomonitor and/or control the length of power supply to equipment tominimize or prevent unwanted operation of said equipment and thepotential damage to the home and/or equipment that may result therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, illustrative embodiments are shown indetail. Although the drawings represent some embodiments, the drawingsare not necessarily to scale and certain features may be exaggerated,removed, or partially sectioned to better illustrate and explain thepresent disclosure. Further, the embodiments set forth herein are notintended to be exhaustive or otherwise limit or restrict the claims tothe precise forms and configurations shown in the drawings and disclosedin the following detailed description.

FIG. 1 is a schematic block diagram of an exemplary system formonitoring and/or controlling power supply to an equipment unit;

FIG. 2 is a schematic block diagram of an exemplary time fault circuitinterrupter of the system of FIG. 1;

FIG. 3 is a schematic side view of an exemplary time fault circuitinterrupter of the system of FIG. 1;

FIG. 4 is a schematic perspective view of the exemplary time faultcircuit interrupter of FIG. 3;

FIGS. 5A-5D is a schematic, ladder logic diagram for operating thesystem of FIG. 1 under different conditions according to one exemplaryapproach;

FIGS. 6A-6D are schematic ladder logic diagrams for operating the systemof FIG. 1 under different conditions according to another exemplaryapproach; and

FIG. 7 is a schematic flow diagram of an exemplary method for operationof the system of FIG. 1.

DETAILED DESCRIPTION

A time fault circuit interrupter may be provided to interrupt a powersupply to an equipment unit, for example, a pump, upon the occurrence ofa trip condition, to provide unwanted operation of the equipment thatmay potentially cause damage to the equipment unit and/or the home inwhich it is installed, for example, flooding of the home. An exemplarytime fault circuit interrupter may include a sensor configured tomonitor a current flow to the equipment unit. The time fault circuitinterrupter may also include a trip mechanism configured to interruptthe current flow. The time fault circuit interrupter may further includea processor in communication with the sensor and the trip mechanism, andthe processor may be configured to cause the trip mechanism to interruptthe current flow when a current flow time has reached a predeterminedtime limit. The time fault circuit interrupter may be incorporated in asystem with a power distributor.

An exemplary method for interrupting a power supply to an equipment unitmay include monitoring, by a processor, a current flow to the equipmentunit. The method may also include tracking, by a processor, a currentflow time that the current flow is being supplied to the equipment unit.The method may further include interrupting, by a trip mechanism, whenthe current flow time has reached a predetermined time limit.

Referring now to the figures, FIG. 1 illustrates a block diagram of anexemplary system 10 for controlling and/or monitoring power supply to anequipment unit 12. The equipment unit 12 may include a motor 14 that mayreceive a current flow, and may be or may include, but is not limitedto, well pumps, air compressors, industrial pumps, fuel deliverysystems, and the like. The system 10 may include a power distributor 16configured to supply power to the equipment unit 12. The powerdistributor 16 may be, but is not limited to, an electrical distributionboard or panel, a receptacle, or the like. The power distributor 16 mayhave a time fault circuit interrupter 18 configured to interrupt thepower supply to the equipment unit 12 under certain conditions. Forexample, the condition may be a set time duration that the power supplyis to be maintained to the equipment unit 12, as described in moredetail hereinafter. While FIG. 1 illustrates the power distributor 16 ashaving only one time fault circuit interrupter 18, it should beappreciated that there may be any number of time fault circuitinterrupters 18, either alone or in combination. In addition, it shouldbe appreciated that the power distributor 16 may have any number ofother components not shown but that are known in the art, including, butnot limited to, circuit breakers, switches, wires, ground bars, neutralbars, and the like.

Referring now to FIGS. 2-4, an exemplary time fault circuit interrupter18 is illustrated. While FIGS. 3 and 4 illustrate the time fault circuitinterrupter 18 as being embodied as a circuit breaker, which may beincorporated in an electrical distribution board, it should beappreciated that the time fault circuit interrupter 18 may beincorporated in any power distribution system, device, or apparatus,including, but not limited to, a receptacle. The time fault circuitinterrupter 18 may be operable with standard utility supplied power,including, but not limited to, 120 volts to ground, 240 volts singlephase, 240 volts three phase, and 480 volts three phase. Further, thetime fault circuit interrupter 18 may have standard current sizing,including, but not limited to, 15 amp, 20 amp, 30 amp, 40 amp, 50 amp,60 amp, 70 amp, 100 amp, 125 amp, 150 amp, 175 amp, and 200 amp.

The time fault circuit interrupter 18 may include a line terminal 20 bywhich the time fault circuit interrupter 18 may receive a current flowfrom a current or power source, e.g., the power distributor 16, at leastone load terminal 22 by which the time fault circuit interrupter 18 maysupply the current flow to the equipment unit 12, and a neutral wire 23that may lead to a neutral bar of a distribution board. The time faultcircuit interrupter 18 may also include a switch 24 configured toselectively open and close the supply of the current flow. The circuitinterrupter 18 may further include a sensor 26 and a trip mechanism 28.The sensor 26 generally may be configured to monitor the current flow tothe equipment unit 12, and may be, but is not limited to, an inductioncoil 26. The trip mechanism 28 generally may be configured to interruptthe current flow by tripping the circuit upon the occurrence of a tripcondition, e.g., the time duration that the current flow is beingsupplied (the current flow time) reaches a predetermined time limit, andmay be, but is not limited to, a trip coil.

The time fault circuit interrupter 18 may further include a circuitboard 30 with at least one processor 32 and at least one memory 34. Theprocessor 32 may be in communication with the sensor 26 and the tripmechanism 28. The processor 32 may receive a signal or other indicationfrom the sensor 26 that current flow is being supplied to the equipmentunit 12. When the processor 32 determines that the current flow time,has been supplied has reached a predetermined time limit, the processor32 may be configured to send a command signal to the trip mechanism 28or otherwise cause the trip mechanism 28 to interrupt the current flowby tripping the circuit. The time fault circuit interrupter 18 mayinclude at least one timer 36 in communication with the processor 32.When the processor 32 receives a signal from the sensor 26 that currentflow is being supplied to the equipment unit 12, the processor 32 maycommand the timer 36 to begin tracking or measuring the current flowtime until the predetermined time limit has been reached. While FIG. 2illustrates the timer 36 as being part of or on the circuit board 30, itshould be appreciated that the timer 36 may be located elsewhere in ahousing 42 of the time fault circuit interrupter 18 in which or on whichthe components may be located.

In embodiments in which the equipment unit 12 is a pump used to fill apool, the time fault circuit interrupter 18 may further include a poolfill mode selector 38, which may be, but is not limited to, a pushbutton. When activated, the selector 38 may engage contacts, causing asignal to be generated and sent to the processor 32 such that theprocessor 32 knows that the pump is operating in a pool fill mode. Thus,the processor 32 may retrieve from the memory 34 and run the logicprogram associated with the pool fill mode. Activation of the selector38 may further activate an indicator 40 that may provide an indicationto a user that the equipment 12 is in the pool fill mode. The indicator40 may be visual and/or auditory, and may include, but is not limitedto, a light emitting diode.

The memory 34 may have stored on it one or more logic programs by whichthe processor 32 may determine if the predetermined time limit has beenreached, and therefore if the circuit and current flow should beinterrupted. The logic program(s) may be specific to the type ofequipment unit 12 to which the current flow is being supplied. Thepredetermined time limit may be included in the logic program, and maybe dependent upon at least one condition and/or operating mode of theequipment unit 12. For example, where the equipment unit 12 is a pump,such as a well pump, the conditions may include one or more of a lowwater flow condition, a medium water flow condition, a high water flowcondition, and a pool fill mode between which the predetermined timelimit may differ. The condition may also be that contacts of theequipment unit 12 are stuck on. Exemplary ladder logic diagrams areillustrated in FIGS. 6A-7E, and are described in more detailhereinafter.

Processor 32 may include a microprocessor. Processor 32 may receiveinstructions from memories such as memory 34, and execute theinstructions, thereby performing one or more operations or processesincluding those described herein. Such instructions may be stored andtransmitted using a variety of computer-readable mediums (e.g., memory34). Processors such as processor 32 may include any computer hardwareor combination of computer hardware that is configured to accomplish thepurpose of the devices, systems, and processes described herein. Forexample, the processor 32 may be any one of, but not limited to single,dual, triple, or quad core microprocessors (on one single chip),graphics processing devices, visual processing devices, and virtualprocessors.

Memories such as memory 34 may include, in general, anycomputer-readable medium (also referred to as a processor-readablemedium) that may include any non-transitory (e.g., tangible) medium thatparticipates in providing medication information or instructions thatmay be read by a computer (e.g., by processor 32). Such a medium maytake many forms, including, but not limited to, non-volatile media andvolatile media. Non-volatile media may include, for example, optical ormagnetic disks and other persistent memory. Volatile media may include,for example, dynamic random access memory (DRAM), which typicallyconstitutes a main memory. Such instructions may be transmitted by oneor more transmission media, including radio waves, metal wire, fiberoptics, and the like, including the wires that comprise a system buscoupled to a processor of a computer. Common forms of computer-readablemedia include, for example, a floppy disk, a flexible disk, hard disk,magnetic tape, any other magnetic medium, a CD-ROM, DVD, any otheroptical medium, punch cards, paper tape, any other physical medium withpatterns of holes, a RAM, a PROM, an EPROM, a FLASH-EEPROM, any othermemory chip or cartridge, or any other medium from which a computer canread.

Referring now to FIGS. 5A-5D, a ladder logic diagram 100 for operatingsystem 10 under different conditions (e.g., high water flow, mediumwater flow, low water flow, contacts stuck on, and pool fill mode) isillustrated according to one exemplary approach. Ladder logic diagram100 may include a plurality of “rungs”, the operations for which aredescribed below for the different conditions. It should be appreciatedthat any of the logic programs stored in the memory 34 and operated bythe processor 32 may include more or less of the conditions. It shouldfurther be appreciated that any of the time intervals and durationsdescribed with ladder logic diagram 100 are for exemplary purposes only,and may be adjustable.

High Flow

Rung 101: Power on/reset (I:00/01) set, energize power on (O:00/01).

Rung 102: Continuously monitor, via an induction coil (A:1), the ACcurrent of the output circuit to an analog input circuit (A:2). When ACcurrent is detected, the analog input circuit (A:2) sends an equalstatement and sets input (I:00/02). On Delay Timer Two (T:2) sets afteran approximate fifteen second preset expires.

Rung 103: With On Delay Timer One (T:1) set, Counter One (C:1) counts uponce every time On Delay Timer Two (T:2) toggles on and off until apreset of approximately 1800 seconds expires. At the same time RetentiveTimer One (RTO:1) sets after an approximate six hour preset expires.

Rung 104: With Counter One (C:1) set, Retentive Timer (RTO:1) set andPool Fill (O:00/03) not set, energize Trip Coil (O:00/02).

Rung 105: With On Delay Timer (T:1) not set, set On Delay Timer Two(T:2). On Delay Timer Two (T:2) sets after an approximate two hourpreset expires.

Rung 106: With On Delay Timer Two (T:2) set, reset Counter Two (C:2) andRetentive Timer One (RTO:1).

Medium Flow

Rung 107: With On Delay Timer One (T:1) set, Counter Two (C:2) counts uponce every time On Delay Timer One (T:1) toggles on and off until apreset of approximately 900 seconds expires. At the same time, RetentiveTimer One (RTO:1) sets after an approximate twelve hour preset expires.

Rung 108: With Counter Two (C:2) set, Retentive Timer Two (RTO:2) set,and Pool Fill (O:00/03) not set, energize Trip Coil (O:00/02).

Rung 109: With On Delay Timer Two (T:2) set, reset Counter Two (C:2) andRetentive Timer Two (RTO:2).

Low Flow

Rung 110: With power on and Counter (C:4) not set, On Delay Timer (T:3)sets after an approximately twelve hour preset expires.

Rung 111: With On Delay Timer One (T:1) set and On Delay Timer Three(T:3) set, then Counter Three (C:3) counts up one and sets after presetexpires.

Rung 112: With On Delay Timer One (T:1) set, Counter Four (C:4) countsup one and sets after preset expires.

Rung 113: With O Delay Timer One (T:1) not set, On Delay Timer Four(T:4) sets after an approximately fifteen hour preset expires.

Rung 114: With Counter Three (C:3) set and Pool Fill (O:00/03) not set,energize Trip Coil (O:00/02).

Rung 115: With Counter Three (C:3) enabled, reset On Delay Timer Three(T:3)

Rung 116: With On Delay Timer Six (T:6) set, reset Counter Three (C:3)

Contacts Stuck On

Rung 117: With On Delay Timer One (T:1) set, On Delay Timer Five (T:5)sets after an approximate two hour preset expires

Rung 118: With On Delay Timer Five (T:5) set and Pool Fill (O:00/03) notset, energize Trip Coil (O:00/02).

Pool Fill

Rung 119: With Momentary Pushbutton (I:00/03) set, and Timer Four (T:4)not set, energize Pool Fill (O:00/03).

Rung 120: With Pool Fill (O:00/03) set, On Delay Timer Six (T:6) setsafter an approximate twenty four hour preset expires.

Rung 121: With Pool Fill (O:00/03) set, and Trip Coil (O:00/02) not set,energize (0:00/03) LED on.

Referring now to FIGS. 6A-6D, a ladder logic diagram 200 for operatingsystem 10 under different conditions (e.g., high water flow, mediumwater flow, low water flow, contacts stuck on, and pool fill mode) isillustrated according to another exemplary approach. Ladder logicdiagram 200 generally may include rungs 201-222, where any one of rungs201-221 may be similar in programming and/or operation as acorresponding rung 101-121 in ladder logic diagram 100. In ladder logicdiagram 200, each condition may have its own output, as illustrated inrungs 204, 208, 214, 218, and 219. In addition, rungs 206, 209, 215, and216 may include the Pool Fill being set, though it should be appreciatedthat more or less rungs may include this logic. Further, at rung 222,with any of the High Flow, Medium Flow, Low Flow, or Contacts Stuck Onconditions set and the Pool Fill not set, the Trip Coil output may beenergized. It should be appreciated that any of the logic programsstored in the memory 34 and operated by the processor 32 may includemore or less of the conditions. It should also be appreciated that anyof the time intervals and durations described with ladder logic diagram200 are for exemplary purposes only, and may be adjustable. It shouldfurther be appreciated that any combination of rungs between ladderlogic diagrams 100 and 200 capable of achieving and performing method300, described below, and/or operating system 10 is contemplated.

Referring now to FIG. 7, an exemplary method 300 for interrupting apower supply to an equipment unit, such as equipment unit 12, upon theoccurrence of a trip condition is illustrated. As explained above, thetrip condition generally may be when a current flow has been suppliedfor a predetermined time limit. While method 300 is described withrespect to system 10, and in particular, time fault circuit interrupter18, it should be appreciated that any system and/or device capable ofperforming the steps of method 100 is contemplated. Method 300 beginsjust after a current flow to the equipment unit 12 begins. At step 302,the sensor 26 may continuously monitor the current flow, andcontinuously send a signal to the processor 32 while the current flow ismaintained. At step 304, the processor 32 may track the current flowtime by initiating a timer 36 when the processor 32 first receives asignal from the sensor 26 that the current flow is active. At step 306,the processor 32 may determine if the current flow time has reached apredetermined time limit, as determined based on one or more of thelogic programs stored in the memory 34. If the predetermined time limithas been reached, then method 300 may proceed to step 308 at which theprocessor 32 may cause (or energize) the trip mechanism 28 to interruptthe current flow (e.g., trip the circuit).

With regard to the processes, systems, methods, heuristics, etc.described herein, it should be understood that, although the steps ofsuch processes, etc. have been described as occurring according to acertain ordered sequence, such processes could be practiced with thedescribed steps performed in an order other than the order describedherein. It further should be understood that certain steps could beperformed simultaneously, that other steps could be added, or thatcertain steps described herein could be omitted. In other words, thedescriptions of processes herein are provided for the purpose ofillustrating certain embodiments, and should in no way be construed soas to limit the claims.

It will be appreciated that the aforementioned method and devices may bemodified to have some components and steps removed, or may haveadditional components and steps added, all of which are deemed to bewithin the spirit of the present disclosure. Even though the presentdisclosure has been described in detail with reference to specificembodiments, it will be appreciated that the various modifications andchanges can be made to these embodiments without departing from thescope of the present disclosure as set forth in the claims. Thespecification and the drawings are to be regarded as an illustrativethought instead of merely restrictive thought.

All terms used in the claims are intended to be given their broadestreasonable constructions and their ordinary meanings as understood bythose knowledgeable in the technologies described herein unless anexplicit indication to the contrary in made herein. In particular, useof the singular articles such as “a,” “the,” “said,” etc. should be readto recite one or more of the indicated elements unless a claim recitesan explicit limitation to the contrary.

1-20. (canceled)
 21. A time fault circuit interrupter comprising: asensor configured to monitor a current flow to an equipment unit; a tripmechanism configured to interrupt the current flow; a processor incommunication with the sensor and the trip mechanism, the processorbeing configured to cause the trip mechanism to interrupt the currentflow when a current flow time has reached a predetermined time limit;and a housing in or on which the sensor, the trip mechanism, and theprocessor are disposed; wherein the equipment unit is an air compressor.22. The time fault circuit interrupter of claim 21, wherein the sensorincludes an induction coil, and the trip mechanism includes a trip coil.23. The time fault circuit interrupter of claim 21, further comprising aswitch configured to open and close the current flow to the equipmentunit.
 24. The time fault circuit interrupter of claim 21, furthercomprising at least one timer in communication with the processor, theat least one timer being configured to measure the current flow time andsend the measurement to the processor.
 25. The time fault circuitinterrupter of claim 24, wherein the timer includes at least one of apneumatic timer, a digital timer, an analog timer, and a pulse timer.26. The time fault circuit interrupter of claim 21, wherein a value ofthe predetermined time limit is based on at least one condition.
 27. Thetime fault circuit interrupter of claim 21, wherein the housing is inthe form of a circuit breaker.
 28. A system comprising a powerdistributor configured to distribute power to at least one equipmentunit, the power distributor having at least one time fault circuitinterrupter including: a sensor configured to monitor a current flow toan equipment unit; a trip mechanism configured to interrupt the currentflow; a processor in communication with the sensor and the tripmechanism, the processor being configured to cause the trip mechanism tointerrupt the current flow when a current flow time has reached apredetermined time limit; and a housing in or on which the sensor, thetrip mechanism, and the processor are disposed; wherein the equipmentunit is an air compressor.
 29. The system of claim 28, wherein thesensor includes an induction coil, and the trip mechanism includes atrip coil.
 30. The system of claim 28, wherein the at least one timefault interrupter further includes a switch configured to open and closethe current flow to the equipment unit.
 31. The system of claim 28,wherein the at least one time fault interrupter further include at leastone timer in communication with the processor, the at least one timerbeing configured to measure the current flow time and send themeasurement to the processor.
 32. The system of claim 31, wherein thetimer includes at least one of a pneumatic timer, a digital timer, ananalog timer, and a pulse timer.
 33. The system of claim 28, wherein avalue of the predetermined time limit is based on at least onecondition.
 34. The system of claim 28, wherein the power distributor isan electrical distribution board.
 35. The system of claim 34, whereinthe housing is in the form of a circuit breaker disposed in theelectrical distribution board.
 36. The system of claim 28, wherein thepower distributor is in the form of a receptacle.
 37. A methodcomprising: monitoring, by a sensor housed in a housing, a current flowto an air compressor; tracking, by a processor, a current flow time thatthe current flow is being supplied to the equipment unit; interrupting,by a trip mechanism housed in the housing, the current flow when thecurrent flow time has reached a predetermined time limit.
 38. The methodof claim 37, wherein the sensor includes an induction coil, and the tripmechanism includes a trip coil.
 39. The method of claim 37, wherein avalue of the predetermined time limit is based on at least onecondition.
 40. The method of claim 37, wherein the housing is in theform of a circuit breaker housed in an electrical distribution board.